Portable and modular energy storage with adjustable waveform characteristics for electric vehicles

ABSTRACT

A power system using multiple battery packs to generate a defined power output may include a plurality of modular battery packs, each of which may include: a first housing, a plurality of battery cells, a first interface that communicates information, and a second interface that transmits power. The power system may also include a second housing configured to removably receive the plurality of modular battery packs and a waveform generation circuit, and a processing system that is configured to receive the information from the battery packs indicating electrical waveform characteristics for power received from each, to cause the waveform generation circuit to aggregate the power received from the modular battery packs, and to cause the waveform generation circuit to generate an output electrical signal based on stored parameters.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/199,835 filed on Jul. 31, 2015, which is incorporatedherein by reference. This application also claims the benefit of U.S.Provisional Patent Application No. 62/368,880 filed on Jul. 29, 2016,which is incorporated herein by reference.

BACKGROUND

The technology revolution of the past two decades has led to manychanges—from the Internet and social media to mobile phones and tablets.What often gets overlooked are the indirect developments that technologyhas enabled. Small, power-hungry devices forced research into newbattery chemistries such as lithium-ion in the 2000s, and nowchemistries are emerging that offer ten times the performance.Technology is enabling the green movement through the Internet of Things(IoT) and the sensors, monitoring, and management capabilities itaffords. Technology is also enabling the automotive industry to developnew vehicle platforms that are cleaner, faster, require lessmaintenance, and soon may not even require a driver. Finally, technologyis enabling the energy and utility industries to migrate fromfossil-fuel power plants and their clients to avail of more efficientand effective delivery and transmission methods. These industries arenow converging around a single concept: energy storage.

BRIEF SUMMARY

In some embodiments, a power system using multiple, independent batterypacks to generate a defined power output may include a plurality ofmodular battery packs. Each of the plurality of modular battery packsmay include: a first housing, a plurality of battery cells enclosed inthe first housing, a first interface that communicates informationassociated with the modular battery pack, and a second interface thattransmits power from the plurality of battery cells. The power systemmay also include a second housing configured to removably receive theplurality of modular battery packs and a waveform generation circuit.The power system may also include a processing system that is configuredto: receive the information from each of the plurality of modularbattery packs, the information indicating electrical waveformcharacteristics for respective power received from each of the pluralityof modular battery packs; cause the waveform generation circuit toaggregate the power received from each of the plurality of modularbattery packs according to the respective electrical waveformcharacteristics; and cause the waveform generation circuit to generatean output electrical signal based on stored parameters.

In some embodiments, the output electrical signal generated by the powersystem may be transmitted to a motor of an electric or hybrid electricvehicle. The power system may also include a multi-tap DC transformer.The output electrical signal may include a DC waveform generated by themulti-tap DC transformer or solid-state power supply, where a voltageand current of the DC waveform may be based on the stored parameters.The power system may also include an AC inverter. The output electricalsignal may include an AC waveform generated by the AC inverter, where avoltage, current, and frequency of the AC waveform may be based on thestored parameters. The information from each of the plurality of modularbattery packs may include a serial number for the respective modularbattery pack. The processing system may be further configured todetermine the electrical waveform characteristics for the respectivepower received from each of the plurality of modular battery packs byusing the serial number to look up the electrical waveformcharacteristics in a memory. The power system may also include a thermalmaterial that is thermally coupled to respective thermal materials eachof the modular battery packs to transfer heat away from the plurality ofbattery cells in each of the modular battery packs. The thermal materialmay include a nonconductive extinguishing agent.

In some embodiments, a method of using a power system with independentbattery packs to generate a defined power output mya include inserting aplurality of modular battery packs into a second housing of the powersystem configured to removably receive the plurality of modular batterypacks. Each of the plurality of modular battery packs may include afirst housing, a plurality of battery cells enclosed in the firsthousing, a first interface that communicates information associated withthe modular battery pack, and a second interface that transmits powerfrom the plurality of battery cells. The method may also includereceiving, at a processing system of the power system, the informationfrom each of the plurality of modular battery packs. The information mayindicate electrical waveform characteristics for respective powerreceived from each of the plurality of modular battery packs. The methodmay additionally include causing, at a processing system of the powersystem, a waveform generation circuit to aggregate the power receivedfrom each of the plurality of modular battery packs according to therespective electrical waveform characteristics. The method may furtherinclude causing, at a processing system of the power system, thewaveform generation circuit to generate an output electrical signalbased on stored parameters.

In some embodiments, the first housing of each of the plurality ofmodular battery packs may be hermetically sealed. The plurality ofbattery cells of at least one of the plurality of modular battery packsmay include a plurality of supercapacitors. The first interface of atleast one of the plurality of modular battery packs may include awireless communication system that communicates wirelessly with thepower system. The second interface of at least one of the plurality ofmodular battery packs may include a transmitter coil that wirelesslytransmits the power from the respective plurality of battery cells tothe waveform generation circuit of the power system. The secondinterface of at least one of the plurality of modular battery packs mayinclude a two-pole wired port that mates with a corresponding two-polewired port of the power system. The volume of the first housing of eachof the plurality of modular battery packs may be at least 0.25 cubicfeet. The method may also include communicating, through the firstinterface of at least one of the plurality of modular battery packs, acharge history of the respective modular battery pack to the processingsystem of the power system. The power from the plurality of batterycells provided to the power system may include a signal of approximately48 VDC and 45 A. The method may also include providing, through thesecond interface of the plurality of modular battery packs, chargingpower, and charging the respective plurality of battery cells of each ofthe plurality of modular battery packs using the charging power.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of the presentinvention may be realized by reference to the remaining portions of thespecification and the drawings, wherein like reference numerals are usedthroughout the several drawings to refer to similar components. In someinstances, a sub-label is associated with a reference numeral to denoteone of multiple similar components. When reference is made to areference numeral without specification to an existing sub-label, it isintended to refer to all such multiple similar components.

FIG. 1 illustrates a power system that includes removable modularbattery packs, according to some embodiments.

FIG. 2 illustrates a simplified diagram of a battery subsystem,according to some embodiments.

FIG. 3 illustrates a power subsystem of a SEC, according to someembodiments.

FIG. 4 illustrates a SEC, according to some embodiments.

FIG. 5 illustrates a housing of a SEC, according to some embodiments.

FIG. 6 illustrates a rear view of the housing of a SEC, according tosome embodiments.

FIG. 7 illustrates a cutaway view of a SEC, according to someembodiments.

FIG. 8 illustrates a power subsystem of a smart power system, accordingto some embodiments.

FIG. 9 illustrates the physical arrangement of a smart enclosure with aplurality of SECs and a smart power system, according to someembodiments.

FIG. 10 illustrates a home charging and storage station, according tosome embodiments.

FIG. 11 illustrates a commercial charging and storage station (CCSS),according to some embodiments.

FIG. 12 illustrates a communication architecture for a CCSS, accordingto some embodiments.

FIG. 13 illustrates a battery subsystem similar to that described inFIG. 2 within an integrated coolant system.

FIG. 14 illustrates a SEC comprising an integrated thermal material,according to some embodiments.

FIG. 15 illustrates a flowchart of a method for providing power througha modular battery pack, according to some embodiments.

FIG. 16 illustrates a flowchart of a method for using a power systemwith independent battery packs to generate a defined power output,according to some embodiments.

DETAILED DESCRIPTION

Described herein, are embodiments for an energy storage solutionincluding an energy module as part of a modular energy platform andecosystem that allows the evolving hybrid car and electric vehicle (EV)industry, along with many other industries, to overcome their currentbattery limitations. Specifically, rather than waiting for an EV torecharge, users can swap out the energy cell modules and be back on theroad in possibly less time than it would take to fill an average gastank. The energy modules may be similar in practice to rechargeablebatteries, but may be constructed in a unique manner that allows forhigh energy density (e.g., on the order of 1 kWh or greater per 10 lbcell or more) using a modular, removable package. This power system isunique in that the energy cell modules may be used across a variety ofindustries and applications.

In some embodiments, a home charging station can use a standardhousehold outlet to charge multiple energy modules since the chargingwindow may be extended significantly compared to the power demands ofcharging a vehicle directly. When returning from a trip, users can swapspent energy modules from an EV with fresh energy modules from the homecharging station instead of waiting for a non-removable battery torecharge. This same concept can be applied to commercial sites,traditional gas stations, and other available sites. A commercialcharging station can store and charge batteries, and through either anautomated kiosk setup or a traditional attendant setup, users can swaptheir spent energy modules with freshly charged units. Unliketraditional gas stations that require large forecourts, storage tanks,special permitting, and environmental challenges, these kiosks that canbe sized to occupy less than a standard parking spot can sit in urbanareas as self-serve fuel stops. For a Commercial Real Estate (CRE)location, these stations can also support a building's emergency powerneeds along with providing a service to their tenants.

This distributed energy storage platform, which can be located in homes,commercial locations, fuel stations, and more, can be an integral partof a utility's demand response (DR) solution. The energy stored in theremovable, modular battery packs can flow back into the grid whenrequired, either during peak load or service outages. They can alsosupport the individual site's power needs, thereby offsetting the peakload demand usage.

The embodiments described herein provide the same energy storagecapacity as found in an EV in a package that weighs 400 lbs or less. Onebenefit of these embodiments is to package these technologies into SmartEnergy Cells (SECs) that range from 5-40 lbs, depending on theirapplication, with a 10 lb module being one module size for the typicalEV. This provides a manageable weight that an average person can lift toswap modules. Since these SECs make the vehicle significantly lighter,it can achieve higher miles/kW, allowing for greater distance, lessbattery capacity, or both. This appeals to people who previously shunnedEVs because of performance concerns.

In one embodiment, a SEC will deliver an approximate 48V output andbetween 1-20 kWh capacity, or more. The 48V output is corresponds to anoperating voltage for most communications infrastructures and othersystems, and would thus increase the number of compatible applications.Using multiples of that voltage, these embodiments can achieve anormalized 120/240 VAC for both residential and commercial applications,and a 336 VDC for the typical EV motor. However, other specific voltagesmay be achieved using the architecture described below.

Each SEC can be constructed by using a common chassis physical envelopethat incorporates cooling capabilities, electronics, electricalconnections, and/or other components. The battery submodules may containbattery cells or supercapacitors that can vary according to evolvingbattery technologies, including lithium ion-sulphur, carbon nanotubes,or potentially even next generation fuel-cells.

FIG. 1 illustrates a power system that includes removable modularbattery packs, according to some embodiments. The system includes aplurality of smart energy cells (SECs) 106. Throughout this disclosure,the SECs 106 may be referred to as “modular battery packs,” “removablemodular battery packs,” and/or “energy modules,” and these terms may beused interchangeably. The SECs 106 represent the basic energy storagecomponents of the power system that allow for the removal and transferof energy storage from devices and systems that consume power, incontrast to existing batteries, for example, for electric vehicles thatare fixed in location and arrangement and require special operations tomove or replace.

Each SEC may include one or more battery subsystems 102. Throughout thisdisclosure, the battery subsystems 102 may also be referred to as“battery submodules (BSM),” and these terms may be used interchangeably.The battery submodules provide a standardized structure/framework tosupport one or more energy storage devices, such as battery cells orsuper capacitors. Each SEC may also include a power subsystem 104. Thepower subsystem 104 may also be referred to as a “communicationsubmodule (CSM),” and these terms may be used interchangeably. The powersubsystems 104 provide a standardized means to aggregate all of theelectrical connections in the SEC and provide a standardized output. Thepower subsystems 104 also manage communications between each of thebattery subsystems 102 and the rest of the power system.

Each SEC may also include a housing, referred to herein as a “firsthousing,” and/or a handle 116. The handle 116 and the housing combine tomake each SEC a removable, modular unit that can be readily removed fromthe power system by a user and replaced with a similar SEC. In someembodiments, the handle 116 on each SEC can be used to carry the SEC,and to lock the SEC in place within the power system by turning ordepressing the handle 116 when the SEC is inserted.

The power system may include a smart enclosure (SE) 110, which may alsobe referred to herein as a “second housing” to distinguish it from thefirst housing of the SECs. The smart enclosure 110 may include a powerbus that links the power provided by each of the SECs to a smart powersystem 108. The smart enclosure 110 may also include a communication bus120 that communicatively couples each of the SECs to the smart powersystem 108. The smart enclosure 110 provides a containment unit andstructure to support a number of SECs along with their respectiveelectrical connections. The smart enclosure 110 provides physical andelectrical couplings that hold the SECs in place and connect the SECs tothe rest of the power system.

The power system may also include a smart power system 118, which mayalso be referred to herein as a “smart power module (SPM)” and/or a“power module (PM).” The smart power system 108 may include a powersubsystem 118 that is similar to the power subsystems 104 of the SECs106. The power subsystem 118 of the smart power system 108 may alsoinclude a housing and handle 116 that is similar to those of the SECs106. Therefore, the smart power system 108 may have a physical formfactor that is similar to or identical to the SECs 106. The powersubsystem 118 of the smart power system 108 can communicate with each ofthe SECs 106 to authenticate their identity and thereby enable the SECs106 to transmit power to the smart power system 108. The power subsystem118 can also communicate with the power subsystems 104 of the SECs 106to identify the electrical characteristics of each of the SECs 106. Thepower subsystem 118 can then aggregate the power provided by each SECand generate a waveform (e.g., VDC, VAC, etc.) corresponding to a set ofstored parameters in the power subsystem 118. The generated waveform canbe transmitted via a power output 124 through the smart enclosure 110 toa load system 114. The load system 114 can, for example, includeelectric vehicles, consumer and/or residential electrical systems, powergrids, and/or the like. Additionally, the power subsystem 118 caninclude a communication output 126 to provide status, diagnostic,historical, and/or command information to/from the load system 114.

FIG. 1 represents a general overview of the power system describedherein. The remainder of this disclosure will describe each of thecomponents and subsystems described above in greater detail.

FIG. 2 illustrates a simplified diagram of a battery subsystem 102,according to some embodiments. Each SEC may include a plurality ofbattery cells that are used to store and provide electrical power. Theplurality of battery cells may be divided into a plurality of groupsthat can be managed as groups. These groups are represented by thebattery subsystem 110. In some embodiments, each SEC may include sevenbattery subsystems 102, or between five and nine battery subsystems 102.

The battery subsystem may include a plurality of individual batterycells 214. In some embodiments, the individual battery cells may beimplemented using lithium-ion 18650 battery cells. In other embodiments,the individual battery cells may also include other storagetechnologies, such as super capacitors. The battery subsystem 102 mayinclude mechanical supports that secure the batteries, either throughfriction fit or a clamping mechanism. Springs or solder connections mayalso be used to secure the battery cells 214 within the batterysubsystem 102. In one embodiment, each battery subsystem 102 may include13 lithium-ion 18650 batteries, or between 10 and 16 lithium-ionbatteries.

The battery subsystem 102 may include a physical housing thatmechanically fastens to the internal structure of the SEC. The housingmay protect the battery cells 214 and keep them fixed in place. In someembodiments, the housing of the battery subsystem 102 may be arectangular cube such that each of the battery subsystems 102 in the SECcan be inserted adjacently within a rectangular cube housing of the SEC.In some embodiments, the battery subsystem 102 may incorporate or beconstructed using an intumescent material for fire protection.

In addition to providing a physical connection for the plurality ofbattery cells 214, the battery subsystem 102 may also include aprocessing system 210 that electrically and/or communicatively couplesthe battery subsystem 102 to the power subsystem of the SEC. A power bus206 can receive the power provided from the battery cells 214, and theprocessing system 210 can perform various functions on the receivedpower. In some embodiments, the processing system may include anovercurrent protection ship that protects the battery cells 214 and therest of the processing system 210 when both charging and discharging thebattery cells 214. The processing system 210 may also include amicrocontroller that communicates through a communication bus 202 andcommunication interface 218 in the housing of the battery subsystem 201with the rest of the SEC. The microcontroller can control the state ofthe battery subsystem 102 with regards to charging and discharging.

The power system 210 may also include a second power bus 208 and a powerinterface 216 in the housing of the battery subsystem 102. In someembodiments, the power bus 208 may be replaced with a dedicated wiredconnection between the SEC and the smart power system 108. The powerinterface 216 can both receive power from the SEC and provide power tothe SEC depending on the state of the processing system 210. During acharging state, a charging circuit can receive power through the powerinterface 216 and charge the battery cells 214. During a dischargingstate, the processing system 210 can receive power from the batterycells 214 and use a DC/DC regulator to provide clean power to the powerinterface 216. The power interface 216 can connect to internal powerrails of the SEC, which can be combined to provide the overallelectrical output of the SEC. The output from each battery subsystem 102may be controlled by the power subsystem of the SEC that governs thestatus, performance, and functionality of the SEC.

In some embodiments, the processing system 210 may also include a memorythat stores lifecycle information for the battery cells 214 and/or forthe battery submodule 102 specifically. The memory can store a number ofcharge/discharge cycles that the battery cells 214 have undergone. Thememory can also store specific voltage/current capabilities of the powercells 214 and of the battery subsystem 102 as a whole. The memory canstore a serial number or other identification number for the batterysubsystem 102. The microcontroller can transmit the serial numberthrough the communication interface 218 to the power subsystem of theSEC, which can then use the serial number to determine the electricalcharacteristics of the battery cells 214. For example, lithium-ionbatteries may have a longer lifetime than super capacitors, but maycharge more slowly. These electrical characteristics can be consideredby the microcontroller when governing the operations of the chargingcircuit. In some embodiments, battery management and monitoringcapabilities may be used to auto-detect the chemistries of the connectthe battery cells. In these embodiments, the processing system 210 canpredict the remaining lifecycle of the battery cells 214.

In some embodiments, the processing system 210 may also include state ofhealth sensors that provide a real-time status of the battery subsystem102. For example, some embodiments may include a temperature sensor thatmonitors the temperature of the battery cells 214. As battery cells aredischarged, they often generate excessive heat that can damage thebattery cells 214 and/or the processing system 210. As will be describedbelow in greater detail, the battery subsystem 102 may include anintegrated cooling system that is configured to extract heat from thebattery cells 214 and transfer the heat to the smart enclosure (secondhousing) of the power system. The temperature sensor of the processingsystem 210 can monitor the temperature of the battery cells 214 in realtime. The microcontroller can then communicate with the power subsystemof the SEC to regulate the flow of coolant through the SEC and/or thebattery subsystem 102. For example, when the temperature increasesaccording to the temperature sensor, the microcontroller can requestcoolant to flow at a higher rate through the battery subsystem 102and/or the SEC. Conversely, when the temperature decreases or is belowan optimal operating temperature, the microcontroller can requestcoolant to flow at a lower rate through the battery subsystem 102 and/orthe SEC. Some embodiments may also include electrical heating coils inthe battery subsystem 102 that can be used to heat the battery cells 214in cold environments.

FIG. 3 illustrates a power subsystem 104 of a SEC, according to someembodiments. The power subsystem 104 provides a standardized means toaggregate all of the electrical connections and provide monitoring andcontrol of the power flow from each of the battery subsystems in theSEC. First, the power subsystem 104 may include a DC combiner circuit302 that is electrically coupled to the power interface 216 of each ofthe battery subsystems in the SEC. The DC combiner circuit can combineeach of the DC voltages from the battery subsystems into a DC signal 328using a ladder of diode-connected circuits.

In some embodiments, a DC/DC converter 322 can be programmed to providevarying levels of DC voltage to the rest of the power system. In someembodiments, the DC/DC converter 322 can provide a 48 V, 45 A signal toa DC port 316. In these embodiments, the native output of each of thebattery subsystems may also be 48 V. The DC/DC converter 322 can beprogrammed, in the case of a failure, to simply provide the raw voltagefrom the DC combiner circuit 302 to the DC port 316.

The DC port 316 can also receive AC or DC voltage from the power system,which can be used to charge the battery subsystems in the SEC. Switches318, 320 can be controlled by a microprocessor 310 to change the stateof the SEC from a discharging mode to a charging mode. A chargingcircuit 338 can selectively provide charging power to each of thebattery subsystems individually. For example, a particular batterysubsystem in the SEC may have discharged more rapidly than the rest, andthe charging circuit 338 can direct the power received through the DCport 316 to that particular battery subsystem. In some embodiments, theDC port 316 may include a wired two-pole output connection (+/−) thatcan be connected in serial/parallel with other SECs.

Some embodiments may also include a wireless power interface to transmitpower to the rest of the power system. The power subsystem 104 mayinclude one or more receiving/transmitting coils 334 connected to awireless power circuit 336. The wireless power circuit 336 can transmitpower from the DC combiner circuit 302 or from the DC/DC converter 322during a discharging state. The wireless power circuit 336 can alsoreceive power that is delivered to the charging circuit 338 during acharging state.

The power subsystem may also include various communication devices thatare used to communicate with both the battery subsystems and the rest ofthe power system external to the SEC. A battery subsystem tocommunication bus 332 can be connected to a wired communication chip 326and used to communicate status/state information to/from each of theindividual battery subsystems. Additionally or alternatively, the powersubsystem 104 may include a wireless communication chip 324, such as aBluetooth chip, a Wi-Fi chip, and/or the like. The wirelesscommunication chip 324 can be used to communicate with the individualbattery subsystems. In some embodiments, both the wired communicationchip 326 and the wireless communication chip 324 may be provided, oneserving as a backup system to the other.

The wireless communication chip 324 may also be used to communicate withthe rest of the power system. For example, the wireless communicationchip 324 can communicate with the power subsystem 118 of the smart powersystem 108 of FIG. 1. Additionally or alternatively, a wiredcommunication chip 312 can communicate via a second wired bus 314 thatis shared with other SECs when communicating with the smart power system108.

The processor 310 can be communicatively coupled to a memory 304 thatstores historical information 306 and configuration information 308 foreach of the battery subsystems in the SEC. The historical information306 may include a number of charge/discharge cycles over the lifetime ofeach battery subsystem, charge/discharge times, times since the lastcharge, discharge/charge rates, manufacturing dates, expirationinformation, and so forth. The configuration information 308 may includeserial numbers and identification numbers, battery/energy cell types,numbers of battery/energy cells, voltage outputs, maximum currents,temperature operating ranges, and so forth.

In some embodiments, the power subsystem 104 can require authenticationinformation to be verified before power is transmitted through the DCport 316. Switch 318 can be opened until proper authenticationinformation is validated. For example, cryptographic keys and/orsignatures may be exchanged between the power subsystem 104 and thesmart power system 108 of FIG. 1. An authentication module 330 canperform algorithms that would be known to one having skill in the art toverify that the power subsystem 104 is authorized to provide powerthrough the DC port 316. Handshake information comprising serial numberidentification and status/state information can be exchanged before thepower subsystem 104 allows power to flow through the DC port 316. Thisauthentication feature can be used to prevent theft and enforcelifecycle requirements on the SEC. Because the SECs are designed to bemodular and removable, these security features may be beneficial. Insome embodiments, the diagnostic systems of the power subsystem 104 andof each of the battery subsystems can detect failures orvoltages/currents that are outside the normal operating range. In thecase of a failure, the processor 310 can open switches 318, 322 todisable the SEC and prevent the SEC from being used. The switches 318,322 can also be closed to prevent power flowing from the SEC when thenumber of charge cycles for the SEC surpasses a threshold, when abattery voltage dips below a threshold voltage, or when the malfunctionis detected in the SEC.

FIG. 4 illustrates a SEC, according to some embodiments. The SECincludes a plurality of battery subsystems 102 (102 a, 102 b, 102 c,etc.), each of which includes a plurality of individual battery cellsand a processing system as described above in relation to FIG. 2. TheSEC may also include a power subsystem 104 as described in relation toFIG. 3. A power bus 408 can electrically couple each of the batterysubsystems 102 with the power subsystem 104. Note that in someembodiments, the power bus 408 may have dedicated connections betweeneach battery subsystem and an individual DC port on the power subsystem104. Additionally, a communication bus 406 can communicatively coupleeach of the battery subsystems 102 to the power subsystem 104.

The SEC may also include a housing 410 that encloses the batterysubsystems 102 and the power subsystem 104. In some embodiments, thehousing 410 of the SEC may be hermetically sealed, such that access tothe internal SEC systems is only available through interfaces in thehousing. A first interface 402 can provide communication for statusand/or command information to/from the SEC. A second interface 404 canprovide a DC voltage from the SEC to the smart power system 108.

FIG. 5 illustrates a housing of a SEC, according to some embodiments.While the physical form and volume of the SEC housing can take any shapeor size, some embodiments may be approximately 0.25 cubic feet. Theseembodiments may be approximately 6″×6″×12″. Other embodiments may beapproximately 0.125 cubic feet. These embodiments may be approximately3″×6″×12″. SECs may be stackable in a Lego-like fashion on top of eachother such that a plurality of SECs can be connected together in amodular fashion and removed/inserted into the rest of the power system.The housing of the SEC may include a mechanically and structurallystrong and thermally conductive material such as aluminum. Internally,the SEC may include a chassis to which all of the subsystems (i.e.,battery subsystems and the power subsystem) can be mechanically fastenedto on both sides. The chassis can be perforated to allow circulation ofa thermal material and for wire connections. In some embodiments, thehousing can use molded material along the sides that inset betweenaluminum panels on the top/bottom where thermal transfer may berequired.

A handle 504 can be used to insert/remove the SEC from the smartenclosure of the power system. Additionally, the handle 504 can also beused as a locking mechanism to ensure physical contact with theinterfaces connecting the SEC with the smart enclosure. By locking theSEC in place, this can guarantee positive engagement between theinterfaces and contact with heat transfer mechanisms and electricalterminals. The locking mechanism may be comprised of a screw through thecenter of the SEC to secure the SEC to the containment unit.Alternatively, the SEC can use locking tabs that extend from the sidesof the SEC upon rotation of the handle 504. The handle can bespring-loaded such that the handle disengages the locking mechanism whenturned. In another embodiment, the SEC may be secured by closing a lid,cover, or other components over the SECs when they are inserted into thesmart enclosure. This locking process may engage a master electricalswitch, allowing no power flow unless properly engaged, or to act as amaster reset on all control, monitoring, and microprocessor activities.

In some embodiments, the housing of the SEC may include a display 502.The display 502 can be implemented using an LED/LCD active/passivedisplay. The display 502 can be used to communicate status or state ofhealth information of the SEC to a user. Alternatively or additionally,the status or state of health information can be transmitted through NFCor other wireless protocols to a user's smart phone or a similar device.In some embodiments, the status or state of health information can betransmitted to an app, web portal, or electrical control unit of anelectric vehicle.

In some embodiments, the SEC may include electrical conductors as partof its frame that can also be used as a means to connect other SEC unitstogether. A pair of guide rails 508 may be used for power transfer withone exposed (typically the negative terminal) and the other recessed.The guide rails 508 can also aid with alignment and stability wheninserting/removing the SEC from the smart enclosure.

To allow for easy repair, replacement, recycling, and upgrades for thebattery subsystems as battery technologies and chemistries advance, thehousing of the SEC may include an accessible cover 506. The cover 506can be formed from one or more pieces on the outer structure of the SECand held in place with fasteners, such as screws. The cover 506 can alsoact as a heat sink between the SEC and the smart enclosure. Inembodiments where the SEC is not hermetically sealed, the cover 506 canbe vented to allow for airflow.

In some embodiments, the SEC may be hermetically sealed or at leastwatertight. As described below, when a dangerous condition such asoverheating is detected, the housing of the SEC can be flooded with anelectrically non-conductive and thermally conductive, and/or fireretardant fluid or material that can absorb heat and prevent any firehazards. In some embodiments, the SEC can be continuously flooded withthese types of materials.

FIG. 6 illustrates a rear view of the housing of a SEC, according tosome embodiments. The housing may include one or more power ports 602,604 that are recessed into the housing to prevent short-circuits. Thepower ports 602, 604 are also offset from the center of the housing toensure correct alignment and polarity upon insertion into the smartenclosure. Alternatively, the guide rails 508 from FIG. 5 may also beused for power transfer as described above.

The housing may also include a communication port 606 that allows forcommunication between the SEC and the smart power system of the smartenclosure. Some embodiments (not shown) that use liquid cooling systemsmay also include valves that are recessed into the housing that canaccept liquid coolant through corresponding ports in the smartenclosure.

The example of FIG. 6 uses wired communication and power ports. However,as described above, other embodiments may use wireless communicationdevices (e.g., Bluetooth, Wi-Fi, NFC, etc.) to communicate between theSEC and the smart power module of the smart enclosure. Additionally,other embodiments may use wireless power transfer between the SEC andthe smart power system of the smart enclosure. Therefore, the wiredcommunication and power ports of FIG. 6 are not meant to be limiting.

FIG. 7 illustrates a cutaway view of a SEC, according to someembodiments. As illustrated, the battery subsystems 106 can be enclosedin respective housings and aligned and/or mounted with in the housing ofthe SEC. This modularity allows for battery subsystems to gain storagecapacity or reduce weight depending on the price/performance criteriafor each application as battery storage chemistries evolve. The batterysubsystem 106 in FIG. 7 includes 15 individual battery cells. Asdescribed above, battery subsystems 106 may include varying numbers ofbattery cells depending on the application.

FIG. 8 illustrates a power subsystem 118 of a smart power system 108,according to some embodiments. The power subsystem 118 may be similar tothe power subsystem 104 of the SECs. The power subsystem 118 may includea DC receiver circuit 802 that aggregates the DC voltage signalsreceived from each of the SECs. A multi-tap transformer 820 can receiveeach of the DC signals from the SECs and generate a final DC output 826based on stored parameters. The DC receiver circuit 802 can receive oneinput connection per SEC which may be made via an electrical busconnector or a molex-type connector for wiring.

The power subsystem 118 can include a memory that stores configurableparameters such that the power subsystem 118 can be programmed toprovide different waveforms. These parameters may form part of an energyprofile that can be authenticated, updated in real-time, and stored. Inaddition to a DC port 826, the power subsystem 118 can include an ACport 824 that is electrically coupled to an AC inverter 818. A processor810 can retrieve stored parameters and determine what type of AC signalshould be generated by the power subsystem 118. For example, theprocessor 810 can access stored parameters that determine thevoltage/current and frequency of an AC output. A load device, such asthe electrical system of electric vehicle can communicate the neededelectrical characteristics of the output of the power system. When thepower subsystem 118 communicates with the load system, it can bedynamically programmed with the proper parameters according to the needsof the load system. For example, the DC output can be configured forbetween 12 and 48 VDC, between 110-336 VAC, and up to 320 A in someembodiments. In some embodiments, the DC ports 826 and the AC port 824can be combined into the same physical connection to the smartenclosure, such that the same two-port interface can be used for bothoutput types.

Like the power subsystems of the SECs, the power subsystem 118 mayinclude a communication bus 814 that is communicatively coupled to eachof the SECs, a wired communication chip 812, and/or a wirelesscommunication chip 814. An authentication module 808 can be coupled tothe processor 810 (or may be an integrated part of the processor 810)and can be used to authenticate communications with the various SECssuch that they are enabled to provide power to the power subsystem 118.A wired communication chip 816 and a communication bus 822 can be usedto communicate with the load device, such as the electrical system ofelectric vehicle to receive configuration parameters.

FIG. 9 illustrates the physical arrangement of a smart enclosure 110with a plurality of SECs 106 and a smart power system 108, according tosome embodiments. As illustrated, the smart power system 108 can beconstructed to have the same form factor as each of the SECs.Specifically, the smart power system 108 may be constructed from amechanically strong and thermally conductive material such as aluminumand have an internal chassis that components can be mechanicallyfastened to on both sides. The housing of the smart power system 108 canincorporate the rotating locking handle to secure the smart power system108 to the smart enclosure 110. The housing of the smart power system108 may also be watertight to allow the unit to be flooded withelectrically nonconductive and thermally conductive fluid that willabsorb heat and act as a fire retardant. As with the SECs describedabove, the body of the smart enclosure 110 may be used as one or morecurrent carrying conductors to reduce the number of electoral connectorsrequired. For example, the body of the smart enclosure 110 may be usedas a negative (−) pole.

When the SECs 106 and the smart power system 108 are inserted into thesmart enclosure 110, the smart power system 108 can process the statusof each of the SECs that are connected to it to monitor the chargelevel, temperature, voltage, current, and so forth. In some embodiments,the smart power system 108 can regulate the flow of power to/from theindividual SECs 106. For example, if one SEC 106 a experiences a voltagesag, the smart power system 108 can take the SEC 106 a off-line andcompensate using other SECs (106 b, 106 c, 106 d). Additionally, thesmart power system 108 can regulate the flow of cooling fluid to each ofthe SECs 106 based on temperature readings and/or requests received fromeach of the SECs 106.

The smart enclosure 110 provides the containment unit with the structureto support each of the SECs 106 and the smart power system 108. Thesmart enclosure 110 also provides electrical and cooling connections asillustrated by FIG. 1. Typically, the smart enclosure 110 can supportbetween three and five SECs 106 and at least one smart power system 108to govern power flow through the system. In some embodiments, the smartenclosure 110 can have an overall form factor that fits within astandard 19 inch IT rack. In some embodiments the SECs may be locatedbetween the rails and skin of an IT enclosure, or within doors or otherbody panels of an electric vehicle. The internal backplane of the smartenclosure 110 includes electrical and/or communication bus connectionsas described above that allow for push-pull connections as the differentmodules are inserted. This can also enable plug-and-play operation asmodules are swapped in and out of the smart enclosure 110.

In some embodiments, the smart enclosure 110 may include a coolant flowsystem that pumps liquid coolant through each of the SECs 106 and/or thesmart power system 108. In some embodiments, the structure of the smartenclosure 110 is hollow to allow cooling to flow and circulate throughthe smart enclosure 110 to remove heat from the modules. For example,instead of pumping coolant through each of the modules in the smartenclosure 110, the smart enclosure can pump coolant through thestructure of the smart enclosure to remove heat from the modulesthemselves. Although not shown, the structure of the smart enclosure 110can include two ports on opposite ends of the unit that allow coolingconnections to be made with a solenoid for flow control. These coolingconnections can be coupled to the cooling system of an electronicvehicle.

In some embodiments, the smart enclosure 110 may include anelectro-mechanical actuator that allows the smart enclosure 110 to beraised and lowered in the application environment. For example, thesmart enclosure 110 can be embedded into a floor or trunk of an electricvehicle. When swapping any of the modules in the smart enclosure 110,the smart enclosure 110 can be raised or lowered such that the modulescan be retrieved from the smart enclosure 110. After swapping, the smartenclosure 110 can be lowered into the floor/trunk of the electricvehicle for convenience.

FIG. 10 illustrates a home charging and storage station (HCSS),according to some embodiments. The HCSS comprises a system that storesSECs and provides charging, net metering, and other managementcapabilities. In practice, the HCSS can be used to store and chargeindividual SECs after they are removed from an electric vehicle. Forexample, when returning home from a drive, a user can remove SECs fromthe smart enclosure of the electric vehicle and place them in the HCSSto be recharged. At the same time, the user can remove charged SECs fromthe HCSS, which can then be inserted into the smart enclosure of theelectric vehicle immediately.

The size of the HCSS can vary, but will typically support at least sixSECs and one smart power system. The internal surface of the HCSS canmirror the SEC profile and have a similar thermal transfer system as thesmart enclosure described above. The HCSS can also include alignment andlocking tabs that can mirror those used by the smart enclosure. Inshort, inserting a SEC into the HCSS can be a very similar experiencefor a user as inserting and SEC into a smart enclosure in an electricvehicle. The HCSS can support additional cooling systems. For example,the HCSS can include fan-assisted air cooling systems and additionalheat sinks that would be too bulky for the smart enclosure.

The HCSS can be connected to a home's electrical power system. Duringtimes of low energy usage by the home, the HCSS can charge the SECsstored therein. During times of high energy usage by the home, the HCSScan draw power from charged SECs to provide additional power to thehome. Additionally, during demand response (DR) events on the localpower grid, the SECs in the HCSS can source additional power to thepower grid to take advantage of DR programs offered by a local utilityprovider. Consequently, the HCSS can incorporate electrical switchgearto prevent backfeeding the grid in the event of a power failure, but canalso support net-metering in cases where on-site generation (wind,solar, etc.) is available. From a utility perspective, the HCSS canincorporate meter sockets and intelligence for smart utility meters andother utility-focused features. For example, the HCSS can include autility meter slot along with provisions to accept conduits anotherservice distribution feeds. The HCSS can function like a basic powersource to provide clean power to the consumer and allow theservice/utility feed to be disconnected and/or supplemented in the eventof a blackout or brownout. The HCSS gateway acts as the communications,monitoring and control hub of the system, which may be deployed as aphysical or virtual machine. Aside from local communications andmonitoring, the system may also support secure back-channelcommunications to form an encrypted, mesh network to allow systems, anddependent, authorized users, to communicate status and general dataacross multiple nodes. This may be supported via wired or wirelesstechnologies, using utility or other communications networks toaggregate data and provide ISP access points. An authorized user,device, or system with the necessary digital certificate and accountstatue may gain universal access to the network.

FIG. 11 illustrates a commercial charging and storage station (CCSS),according to some embodiments. As with the HCSS described above, theCCSS comprises a system that stores SECs (and therefore energy), andprovides charging, net-metering, and other management capabilities. Thismay be similar in function to the HCSS, but the CCSS can operate at alarger scale and capacity. For example, the CCSS may typically be of asufficient size to support up to 500 SECs, and may be the size of a 20foot shipping container. Inside the CCSS, SECs can be mounted afloor-standing 19″ rack that can be up to approximately 7 feet tall.Each rack can include a smart power system that supports and manages allof the SECs in that rack. At the top of each rack, one or more coolingmanifolds may be provided (e.g., one for supply, one for return) toconnect to each of the cooling fluid ports on the SECs. A heat exchangercan cool the circulated coolant fluid.

In one commercial embodiment, the CCSS can support up to 1 MWh ofcapacity, 3-phase power, and a 480V AC input/output with a 48V DC feed.As with the HCSS, the CCSS can function like a basic power source toprovide clean power to the consumer, and allow the service/utility feedto be disconnected and/or supplemented in the event of a blackout orbrownout. Because of its large capacity, the CCSS can be a valuableresource in the utility company's DR strategy. Since the typical CCSSwill be on the order of several hundred kWh of capacity and highlydistributed, they avoid major utility upgrades and redesign.

In some embodiments, the CCSS can be fully automated like a gas orservice station for traditional vehicles. The CCSS can include anautomated self-service interface 1100 akin to an ATM at a bank or creditcard payment system at a gas pump. The interface 1100 allows a user toexchange discharged SECs for freshly charged SECs through a guided,automated process. The discharged SEC may be placed into a slot/chute,and a freshly charged SEC can be returned in its place. Within the CCSS,a robotic arm can take the discharged SEC and place it in an open slot,allowing it to recharge. The robotic arm can then place a freshlycharged SEC back in the user slot. Alternatively, the CCSS may forgo theuse of robotics and allow an attendant to manually handle thetransaction.

FIG. 12 illustrates a communication architecture for a CCSS 1200,according to some embodiments. As described above, a plurality of SECs106 can be stored in the CCSS 1200 and governed by at least one smartpower system 108. A smart cell gateway 1206 can act as a networkinterface and data management hub for the on-site infrastructure of theCCSS. The Gateway can receive input from various sensors within the SECs106, the smart power system 108, and/or the CCSS 1200. The gateway 1206can also provide local control, continuity, and/or autonomy in the eventof a network outage. The gateway 1206 can also be mounted in thestandard 19″ rack within the enclosure of the CCSS 1200.

The smart power system 108 manages how energy is delivered to/from eachof the connected SECs 106. The smart power system 108 can also retrievestatus and/or configuration information from each of the SECs 106. TheGateway 1206 can then transmit the status/configuration information to alocal customer database 1208. The Gateway 1206 can also transfer thisinformation through the Internet 1202 to a smart cell data center 1204.The data center 1204 can universally store information for each of theSECs registered with the smart cell system. This can also allow othervendors to log into the data center 1204 to locate different SECs andmonitor their performance.

As described briefly above, each of the SECs, battery subsystems, andsmart power systems may include integrated cooling systems to removeheat from the battery cells. FIG. 13 illustrates a battery subsystemsimilar to that described in FIG. 2 with an integrated coolant system.In this embodiment, the battery subsystem may include a thermal material1310 that is disposed adjacent to the battery cells 214 such that heatcan be transferred from the battery cells 214 outside of the batterysubsystem. In some embodiments, the thermal material may include a solidmaterial that is thermally conductive and injected into the batterysubsystem to substantially fill gaps and spaces between the batterycells 214 and the housing of the battery subsystem. This thermalmaterial can then transfer heat from the battery cells 214 through thethermally conductive housing of the battery subsystem. The thermalmaterial may also include gels or thermal greases that can fill emptyspace within the battery subsystem. The thermal material may alsoinclude a vapor compression that evaporates a liquid that is thencondensed away from the battery cells.

The thermal material may also include tubing 1304 that allows liquidcoolant to flow through the battery subsystem. In some embodiments, thetubing 1304 can be wrapped around individual battery cells 214 or groupsof battery cells 214 to absorb a maximal amount of heat. The tubing 1304can be coupled to a pair of connectors 1306, 1308 that can be attachedto an external coolant flow system.

FIG. 14 illustrates a SEC 106 comprising an integrated thermal material,according to some embodiments. Like the battery subsystem describedabove, the SEC 106 can also include a thermal material 1410 that isinjected into the housing of the SEC to substantially fill any gapsbetween the battery subsystems 102, the power subsystem 104, and thehousing of the SEC. The thermal material may include a solid thermallyconductive material. The thermal material may also include gels orthermal grease is that couple the internal components of the SEC 106with the housing of the SEC.

Similar to the battery subsystem, the thermal material 1410 of the SEC106 may also include tubing 1406 and/or liquid coolant that iscirculated through the SEC 106. A pair of connectors 1404, 1402 can beconnected to the tubing 1406 and configured to receive liquid coolantthat is pumped and provided by the smart enclosure. For example,connector 1402 may comprise an input port, and connector 1404 maycomprise an output port. In some embodiments, the tubing 1406 can bewrapped around each of the individual battery subsystems 106 to extractheat from the battery subsystems 106. In some embodiments, the tubingcan connect to connectors, such as connectors 1306, 1308 in FIG. 13 oneach of the battery subsystems. Thus, coolant can flow from the smartenclosure to the tubing 1406 of the SEC, then into the tubing 1304 ofeach of the battery subsystems. Connectors 1402 and 1404 may comprisepush-pull connectors that can couple automatically as the SEC 106 isinserted into the smart enclosure.

FIG. 15 illustrates a flowchart of a method for providing power througha modular battery pack, according to some embodiments. The method mayinclude inserting the modular battery pack into a second housing (1502).The modular battery pack may be one of the SECs described above, and thesecond housing may include the smart enclosures described above. Themodular battery pack may include a first housing such as the housing ofthe SECs described above, and may have a volume of at least 0.125 cubicfeet or 0.25 cubic feet. The second housing of the smart enclosure maybe configured to removably receive a plurality of modular battery packsin the form of SECs.

The method may also include communicating, through a first interface ofthe modular battery pack, a status of the modular battery pack to thesecond housing (1504). The method may further include aggregating,through a processing system of the modular battery pack, power from aplurality of battery cells enclosed in the first housing (1506). Theplurality of battery cells may provide at least 1 kW. Furthermore, theprocessing system of the modular battery pack may include the powersubsystem of the SECs described above. The aggregated power mayrepresent a DC signal transmitted from the SEC to the smart power systemof the smart enclosure described above.

The method may further include providing, through a second interface ofthe modular battery pack, the aggregated power from the plurality ofbattery cells from the processing system to the second housing (1508).The first interface of the modular battery pack may include thecommunication port of the SEC that is connected to the smart enclosure.The second interface of the modular battery pack may include the powerinterface of the SEC that is connected to the smart enclosure.

The method may further include transferring heat away from the pluralityof battery cells using a thermal material enclosed in the first housing(1510). The thermal material may include a thermally conductive solid,gel, and/or grease. The thermal material may also include tubing and/orliquid coolant. The thermal material may be circulated through themodular battery pack. Additionally, the thermal material may draw heataway from the battery pack and expel the heat through the first housingof the modular battery pack into the smart enclosure.

It should be appreciated that the specific steps illustrated in FIG. 15provide particular methods of providing power through modular batterypack according to various embodiments of the present invention. Othersequences of steps may also be performed according to alternativeembodiments. For example, alternative embodiments of the presentinvention may perform the steps outlined above in a different order.Moreover, the individual steps illustrated in FIG. 15 may includemultiple sub-steps that may be performed in various sequences asappropriate to the individual step. Furthermore, additional steps may beadded or removed depending on the particular applications. One ofordinary skill in the art would recognize many variations,modifications, and alternatives.

FIG. 16 illustrates a flowchart of a method for using a power systemwith independent battery packs to generate a defined power output,according to some embodiments. The method may include inserting aplurality of modular battery packs into a second housing of the powersystem (1602). The second housing of the power system may include thesmart enclosure described above, and the plurality of modular batterypacks may include a plurality of SECs described above. Each of themodular battery packs may include a first housing, a plurality ofbattery cells, a first interface that communicates informationassociated with the modular battery pack, and a second interface thattransmits power from the plurality of battery cells in the modularbattery pack.

The method may also include receiving, at a processing system of thepower system, the information from each of the plurality of modularbattery packs (1604). The processing system of the power system mayinclude the smart power system 108 described in FIG. 1 and elsewherethroughout this disclosure. The information may indicate electricalwaveform characteristics for the power received from each of the modularbattery packs. For example, the information may include a serial numberthat can be used to look up voltage/current characteristics and/orbattery types for each of the SECs.

The method may additionally include causing, at a processing system ofthe power system, a waveform generation circuit to aggregate the powerreceived from each of the plurality of modular battery packs accordingto the respective electrical waveform characteristics (1606). The methodmay further include causing, at a processing system of the power system,the waveform generation circuit to generate an output electrical signalbased on stored parameters (1608).

It should be appreciated that the specific steps illustrated in FIG. 16provide particular methods of using a power system with independentbattery packs according to various embodiments of the present invention.Other sequences of steps may also be performed according to alternativeembodiments. For example, alternative embodiments of the presentinvention may perform the steps outlined above in a different order.Moreover, the individual steps illustrated in FIG. 16 may includemultiple sub-steps that may be performed in various sequences asappropriate to the individual step. Furthermore, additional steps may beadded or removed depending on the particular applications. One ofordinary skill in the art would recognize many variations,modifications, and alternatives.

In the foregoing description, for the purposes of explanation, numerousspecific details were set forth in order to provide a thoroughunderstanding of various embodiments of the present invention. It willbe apparent, however, to one skilled in the art that embodiments of thepresent invention may be practiced without some of these specificdetails. In other instances, well-known structures and devices are shownin block diagram form.

The foregoing description provides exemplary embodiments only, and isnot intended to limit the scope, applicability, or configuration of thedisclosure. Rather, the foregoing description of the exemplaryembodiments will provide those skilled in the art with an enablingdescription for implementing an exemplary embodiment. It should beunderstood that various changes may be made in the function andarrangement of elements without departing from the spirit and scope ofthe invention as set forth in the appended claims.

Specific details are given in the foregoing description to provide athorough understanding of the embodiments. However, it will beunderstood by one of ordinary skill in the art that the embodiments maybe practiced without these specific details. For example, circuits,systems, networks, processes, and other components may have been shownas components in block diagram form in order not to obscure theembodiments in unnecessary detail. In other instances, well-knowncircuits, processes, algorithms, structures, and techniques may havebeen shown without unnecessary detail in order to avoid obscuring theembodiments.

Also, it is noted that individual embodiments may have been described asa process which is depicted as a flowchart, a flow diagram, a data flowdiagram, a structure diagram, or a block diagram. Although a flowchartmay have described the operations as a sequential process, many of theoperations can be performed in parallel or concurrently. In addition,the order of the operations may be re-arranged. A process is terminatedwhen its operations are completed, but could have additional steps notincluded in a figure. A process may correspond to a method, a function,a procedure, a subroutine, a subprogram, etc. When a process correspondsto a function, its termination can correspond to a return of thefunction to the calling function or the main function.

The term “computer-readable medium” includes, but is not limited toportable or fixed storage devices, optical storage devices, wirelesschannels and various other mediums capable of storing, containing, orcarrying instruction(s) and/or data. A code segment ormachine-executable instructions may represent a procedure, a function, asubprogram, a program, a routine, a subroutine, a module, a softwarepackage, a class, or any combination of instructions, data structures,or program statements. A code segment may be coupled to another codesegment or a hardware circuit by passing and/or receiving information,data, arguments, parameters, or memory contents. Information, arguments,parameters, data, etc., may be passed, forwarded, or transmitted via anysuitable means including memory sharing, message passing, token passing,network transmission, etc.

Furthermore, embodiments may be implemented by hardware, software,firmware, middleware, microcode, hardware description languages, or anycombination thereof. When implemented in software, firmware, middlewareor microcode, the program code or code segments to perform the necessarytasks may be stored in a machine readable medium. A processor(s) mayperform the necessary tasks.

In the foregoing specification, aspects of the invention are describedwith reference to specific embodiments thereof, but those skilled in theart will recognize that the invention is not limited thereto. Variousfeatures and aspects of the above-described invention may be usedindividually or jointly. Further, embodiments can be utilized in anynumber of environments and applications beyond those described hereinwithout departing from the broader spirit and scope of thespecification. The specification and drawings are, accordingly, to beregarded as illustrative rather than restrictive.

Additionally, for the purposes of illustration, methods were describedin a particular order. It should be appreciated that in alternateembodiments, the methods may be performed in a different order than thatdescribed. It should also be appreciated that the methods describedabove may be performed by hardware components or may be embodied insequences of machine-executable instructions, which may be used to causea machine, such as a general-purpose or special-purpose processor orlogic circuits programmed with the instructions to perform the methods.These machine-executable instructions may be stored on one or moremachine readable mediums, such as CD-ROMs or other type of opticaldisks, floppy diskettes, ROMs, RAMs, EPROMs, EEPROMs, magnetic oroptical cards, flash memory, or other types of machine-readable mediumssuitable for storing electronic instructions. Alternatively, the methodsmay be performed by a combination of hardware and software.

What is claimed is:
 1. A power system using multiple, modular batterypacks to generate an output electrical signal, the power systemcomprising: a plurality of modular battery packs, wherein each of theplurality of modular battery packs comprises: a first housing; aplurality of battery cells enclosed in the first housing; a firstinterface that communicates information associated with the modularbattery pack; and a second interface that transmits power from theplurality of battery cells; a power module comprising: a third housingthat has a same form factor as the first housing of at least one of theplurality of modular battery packs; a waveform generation circuitenclosed in the third housing; and a processing system enclosed in thethird housing that is configured to: receive the information from eachof the plurality of modular battery packs, the information indicatingelectrical waveform characteristics for respective power received fromeach of the plurality of modular battery packs; cause the waveformgeneration circuit to aggregate the power received from each of theplurality of modular battery packs according to the respectiveelectrical waveform characteristics; and cause the waveform generationcircuit to generate the output electrical signal based on storedparameters wherein the stored parameters define at least a voltage ofthe output electrical signal; and a second housing configured toremovably receive the plurality of modular battery packs and removablyreceive the power module, the second housing comprising: a plurality ofopenings in a front face of the second housing into which the pluralityof modular battery packs and the power module can be inserted; abackplane on a back face of the second housing that is opposite of thefront face, wherein each of the plurality of modular battery packs andthe power module connect to the backplane when inserted through theplurality of openings.
 2. The power system of claim 1, wherein theoutput electrical signal generated by the power system is transmitted toa motor of an electric or hybrid electric vehicle.
 3. The power systemof claim 1, further comprising a multi-tap DC transformer.
 4. The powersystem of claim 3, wherein the output electrical signal comprises a DCwaveform generated by the multi-tap DC transformer or solid-state powersupply, wherein a voltage and current of the DC waveform is based on thestored parameters.
 5. The power system of claim 1, further comprising anAC inverter.
 6. The power system of claim 5, wherein the outputelectrical signal comprises a AC waveform generated by the AC inverter,wherein a voltage, current, and frequency of the AC waveform is based onthe stored parameters.
 7. The power system of claim 1, wherein theinformation from each of the plurality of modular battery packscomprises a serial number for the respective modular battery pack. 8.The power system of claim 7, wherein the processing system is furtherconfigured to determine the electrical waveform characteristics for therespective power received from each of the plurality of modular batterypacks by using the serial number to look up the electrical waveformcharacteristics in a memory.
 9. The power system of claim 1, furthercomprising a thermal material that is thermally coupled to respectivethermal materials each of the modular battery packs to transfer heataway from the plurality of battery cells in each of the modular batterypacks.
 10. The power system of claim 9, wherein the thermal materialcomprises a nonconductive extinguishing agent.
 11. A method of using apower system with modular battery packs to generate an output electricalsignal, the method comprising: providing a second housing of the powersystem configured to removably receive a plurality of modular batterypacks and removably receive a power module, the second housingcomprising: a plurality of openings in a front face of the secondhousing into which the plurality of modular battery packs and the powermodule can be inserted; a backplane on a back face of the second housingthat is opposite of the front face, wherein each of the plurality ofmodular battery packs and the power module connect to the backplane wheninserted through the plurality of openings; removably inserting theplurality of module battery packs into the second housing of the powersystem, wherein each of the plurality of modular battery packscomprises: a first housing; a plurality of battery cells enclosed in thefirst housing; a first interface that communicates informationassociated with the modular battery pack; and a second interface thattransmits power from the plurality of battery cells; removably insertingthe power module into the second housing, wherein the power modulecomprises; a third housing that has a same form factor as the firsthousing of at least one of the plurality of modular battery packs; awaveform generation circuit enclosed in the third housing; and aprocessing system enclosed in the third housing; receiving, at theprocessing system of the power module, the information from each of theplurality of modular battery packs, the information indicatingelectrical waveform characteristics for respective power received fromeach of the plurality of modular battery packs; causing, at theprocessing system of the power module, the waveform generation circuitto aggregate the power received from each of the plurality of modularbattery packs according to the respective electrical waveformcharacteristics; and causing, at the processing system of the powermodule, the waveform generation circuit to generate the outputelectrical signal based on stored parameters, wherein the storedparameters define at least a voltage of the output electrical signal.12. The method of claim 11, wherein the first housing of each of theplurality of modular battery packs is hermetically sealed.
 13. Themethod of claim 11, wherein the plurality of battery cells of at leastone of the plurality of modular battery packs comprises a plurality ofsupercapacitors.
 14. The method of claim 11, wherein the first interfaceof at least one of the plurality of modular battery packs comprises awireless communication system that communicates wirelessly with thepower system.
 15. The method of claim 11, wherein the second interfaceof at least one of the plurality of modular battery packs comprises atransmitter coil that wirelessly transmits the power from the respectiveplurality of battery cells to the waveform generation circuit of thepower system.
 16. The method of claim 11, wherein the second interfaceof at least one of the plurality of modular battery packs comprises atwo-pole wired port that mates with a corresponding two-pole wired portof the power system.
 17. The method of claim 11, wherein the volume ofthe first housing of each of the plurality of modular battery packs isat least 0.25 cubic feet.
 18. The method of claim 11, further comprisingcommunicating, through the first interface of at least one of theplurality of modular battery packs, a charge history of the respectivemodular battery pack to the processing system of the power system. 19.The method of claim 11, wherein the power from the plurality of batterycells provided to the power system comprises a signal of approximately48 VDC and 45 A.
 20. The method of claim 11, further comprising:providing, through the second interface of the plurality of modularbattery packs, charging power, and charging the respective plurality ofbattery cells of each of the plurality of modular battery packs usingthe charging power.